Internal combustion engine with integral stator and regulator

ABSTRACT

An alternator assembly for an internal combustion engine includes a regulator whose individual circuit components are mounted directly on the stator of the alternator assembly. The regulator may be in the form of discrete components or integrated circuit chips. The components of the regulator circuit may be mounted to the stator by fasteners or by an adhesive resin such as epoxy.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of copending application Ser.No. 07/327,510 filed Mar. 22, 1989, now U.S. Pat. No. 4,915,068.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention relates to an internal combustion engine, and moreparticularly to an alternator assembly for an internal combustionengine.

The regulator of an alternator assembly used in connection with internalcombustion engines typically functions to rectify current produced bythe alternator assembly from alternating current to direct current sothat the battery used on a vehicle such as an automobile, riding lawnmower, airplane, tractor or the like, may be recharged. Thereafter, theregulator functions to prevent the battery from overcharging. Thebattery also functions to feed direct current directly to the headlightsor other lamps of a vehicle as well as other accessories such as aradio, solenoid, brakelights, and the like.

Normally, the regulator comprises a plurality of individual discreteelectrical components combined to form a desired circuit and containedwithin a housing or casing which is mounted externally of and separatelyfrom the alternator assembly. The regulator may be found either on thevehicle frame (automobile, riding mowers, airplanes, tractors, etc.) oron the engine itself. As a result, regulators require their ownindividual assembly time and labor. Oftentimes regulators may alsorequire special mounting brackets and/or fasteners depending upon theparticular engine design which increases the relative cost of such adevice.

In accordance with the present invention, the individual discreteelectrical components of an engine monitoring circuit, preferably aregulator, are mounted directly on the stator of the alternator assemblyfor an internal combustion engine. The advantages of mounting thecircuit components, particularly the regulator circuit components,directly on the stator include numerous cost advantages such as thesavings on fasteners, assembly time and labor, elimination of specialmounting brackets as well as special blower housings (required forregulator mounting in small engine applications such as lawn mowers),elimination of unnecessary wires and connectors as well as the time andlabor to assemble such components, and elimination of the regulator caseand potting material. Additionally, one particular advantage of thepresent invention is that it reduces the overall contour of the engine,especially its height or width, since a separate case or module housingfor example the regulator circuit or charge indicator circuit need notbe provided exteriorly of the engine. Furthermore, higher reliabilityresults due to fewer connections and wires, and high quality ismaintained due to cooler operation of the circuit, especially in smallengine applications, e.g. forced air from the flywheel cools the statorand regulator components versus prior methods involving heat conductionthrough the regulator case or housing.

The circuit components may be assembled to the stator with fastenermeans such as rivets, bolts or screws or by adhesive means such as epoxyresin covering at least a portion of the circuit components. The use ofepoxy also eliminates excessive vibration of the circuit components thuseliminating failures due to vibration breakage. Additionally, thecircuit itself may be composed of a plurality of discrete components orintegrated circuit chips, and may comprise any type of engine monitoringcircuit employed with an internal combustion engine. Preferably, thepresent invention is employed with small internal combustion engines ofthe type utilized in lawn and garden equipment having both half wave aswell as full wave regulator/stator circuits. The regulator may alsoincorporate a charge indicator circuit. Such a circuit is used to turnon a red bulb when the battery voltage is below some set voltage (forexample 12 volts) or a green bulb when the battery voltage is above theset voltage.

Other engine monitoring circuits may also be mounted directly on thestator. Such circuits may include, for example, safety interlockcircuits, oil pressure start circuits, tachometer circuits, engine hourmetering circuits, overheat circuits, and other similar circuitry.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate the best mode presently contemplated of carryingout the invention.

In the drawings:

FIG. 1 is a perspective view of a stator of an alternator assembly foran internal combustion engine incorporating the regulator of the presentinvention;

FIG. 2 is an enlarged fragmentary side view in elevation of the statoralong the plane of the line 2--2 in FIG. 1 illustrating the location ofthe components of the regulator;

FIG. 3 is a schematic circuit diagram of a half wave regulator/statorcircuit;

FIG. 4 is a view similar to FIG. 2 illustrating a second embodimentwherein the components of the regulator are integrated circuits;

FIG. 5 is a schematic circuit diagram of a third embodiment illustratinga full wave regulator/stator circuit;

FIG. 6 is a schematic circuit diagram of a fourth embodimentillustrating another full wave regulator/stator circuit;

FIG. 7 is a top plan view of a stator of an alternator assembly for aninternal combustion engine wherein the components of the regulator ofthe present invention are contained on a bracket mounted on the stator;

FIG. 8 is a fragmentary side view in elevation of the bracket andregulator components illustrated in FIG. 7;

FIG. 9 is a side view in elevation of an alternate bracket assembly forthe embodiment of FIG. 7;

FIG. 10 is a top plan view of the stator of an alternator assembly foran internal combustion engine incorporating a regulator in the form of acircuit board; and

FIG. 11 is an enlarged fragmentary side view illustrating the mountingof the circuit board illustrated in FIG. 10 to the stator.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, FIG. 1 illustrates a stator generallydesignated by the numeral 1 of an alternator assembly for an internalcombustion engine (not shown). It should specifically be understood thatthe term "alternator assembly" as used herein encompasses not onlyalternators but also generators used in connection with internalcombustion engines. Additionally, although FIG. 1 illustrates one designof a stator employed with such an alternator assembly, it is to beunderstood that the present invention may be employed with numerousstator designs and FIG. 1 is illustrative of only one such design.

Stator 1 includes a stationary annular ring member 2 having an innersurface 3 and an outer surface 4. Stator 1 is typically mounted in astationary position disposed concentric with the axis of rotation of anengine's crankshaft (not shown). As shown best in FIG. 1, stator 1includes a plurality of spaced windings or wire coils 5 arrangedcircumferentially about outer surface 4. Coils 5 cooperate in theconventional manner with a moving magnetic field for producing anelectric output current therein. The magnetic field is typicallyprovided by a plurality of rotating magnets 6 (only one of which isshown in FIG. 1) arranged in opposing relation to wire coils 5 anddisposed concentric therewith. As shown best in FIG. 1, rotating magnets6 are mounted on an inner surface 7 of rotating flywheel 8 (shown inphantom lines). Flywheel 8 is connected to the engine's crankshaft inany conventional manner and typically is in the shape of a cup so thatmagnets 6 may be disposed opposite wire coils 5, as is conventional.Stator 1 also includes four lands 9 projecting from outer surface 4 andintegral therewith which provide a means for mounting stator 1 in astationary position on the engine by means of screws 10.

Referring now to FIG. 3, the alternator assembly includes a regulatorwhose schematic circuitry is designated by the numeral 11. Regulator 11may be of any conventional design, and may be in the form of discretecomponents (FIG. 3) or integrated circuit chips (FIG. 4). Regulator 11,as illustrated in FIG. 3, is for illustrative purposes only, andillustrates a schematic diagram for a half wave regulator/stator circuitincorporating a charge indicator circuit, which is an optional add-oncircuit in many regular circuits. More particularly, FIG. 3 illustratescircuit means including a plurality of discrete components connected toa wire coil 5 to regulate the output current therein. More specifically,the discrete components include a one hundred volt twelve amp RMS SCRdevice 12 connected to one terminal of coil 5 together with a one amp,six hundred volt diode 13, a second one amp six hundred volt diode 14and a fourteen volt, one watt zener diode 15 connected to the otherterminal of coil 5. Additionally, a one hundred ohm one watt resistor 25is connected across SCR 12 and diode 13 so as to be connected on oneside between the anode of SCR 12 and coil 5 and its other side betweendiode 13 and diode 14. As noted previously, the circuit illustrated inFIG. 3 is conventional and described for illustrative purposes onlysince other designs are possible. One such alternate design isillustrated in FIG. 4 where a portion of the discrete components of theregulator circuit of FIG. 3 has been replaced by integrated circuitchips 16 and 26 mounted in receptacles 27 and 28, respectively.

Referring now to FIG. 2, there is illustrated the manner in which thecomponents of regulator 11 are mounted directly on stator 1. Asillustrated, components 12-15 and 25 are arranged longitudinally withrespect to one another and mounted so as to engage or bear against outersurface 4 of stator 1. In order to securely mount the components ofregulator 11 on stator 1, one end of the regulator circuit is attachedto a terminal 17 which in turn is mounted to one of the lands 9 by meansof a screw fastener 18. The other end comprising the tab of SCR 12 ofthe regulator circuit is similarly mounted to another land 9 by a screwfastener 20. An adhesive such as an epoxy resin 21 may also be employedwith or without fasteners 18, 20 to mount regulator 11 to stator 1.Epoxy 21 not only adhesively attaches the components of regulator 11 toouter surface 4 of stator 1, but also eliminates vibration of thevarious components so as to prevent vibration breakage of the componentsor wires therebetween.

As illustrated in FIG. 3, regulator 11 includes a polarized plug 22 forconnecting the output current from coils 5 to a charge indicator bulb 24which is controlled in a conventional manner by a charge indicatorcircuit 19. Circuit 19 is a standard optional add-on circuit readilyavailable from numerous sources such as Wells Corp. or Tympanium Corp.,as is well known in the art. Plug 22 is polarized to prevent improperconnections. Thus, plug 22 represents the only external connection fromstator 1. As is typical, the output current from coils 5 as regulated byregulator 11, may be employed to provide battery charging current andtherefore one terminal of the two connector plug leads to battery 23.The other terminal of plug 22 feeds directly to charging indicator bulb24. Other accessories such as headlamp 29 can be connected directly tothe battery 23 or connected through a switch 30.

It should be noted that other engine monitoring circuits may also bemounted directly on stator 1 in addition to regulator circuit 11. Suchcircuits may include, for example, safety interlock circuits, oilpressure start circuits, tachometer circuits, engine hour meteringcircuits, overheat circuits, and other similar circuitry. Safetyinterlock circuits are well known in the art and include those that killthe engine of a lawn mower upon releasing the bail of a walk behindmower or upon getting off the seat of a riding mower. A typical exampleis shown in Kronich et al U.S. Pat. No. 4,394,893. Oil pressure startcircuits are also well known in the art and include those that kill theengine upon sensing low oil pressure, but allow restarting when normaloil pressure is sensed. Tachometer circuits are also well known andtypically comprise those that sense and display engine speed. Enginehour metering circuits are well known and are used to count and displaythe number of hours an engine has actually been in operation. Finally,overheat circuits are also well known and are typically used to shutdown or kill an engine or turn on a warning red light when an engineruns hotter than a desired temperature.

Referring now to FIG. 5, there is illustrated a schematic diagram for afull wave regulator/stator circuit. More particularly, FIG. 5illustrates circuit means including a plurality of discrete componentsconnected to a wire coil 40 which will regulate the output currenttherein. The discrete components include a 100 volt 12 amp RMS SCRdevice 41 connected to one terminal of coil 40 with a 1 amp, 600 voltdiode 42, a second 1 amp 600 volt diode 43 and a 14 volt, 1 watt zenerdiode 44 connected to ground. Additionally, a 100 ohm 1 watt resistor 45is connected across SCR 41 and diode 42 so as to connect it on one sidebetween the anode of SCR 41 and coil 40 on its other side between diode42 and diode 43. An identical circuit to the one just described isconnected to the opposite terminal of coil 40 and includes an SCR 46,diodes 47 and 48, zener diode 49 and resistor 50. As noted previously,the circuit illustrated in FIG. 5 is conventional and described forillustrated purposes only since other designs are possible.

Referring now to FIG. 6, there is illustrated another circuit diagramfor an alternate full wave regulator/stator circuit. More particularly,FIG. 6 illustrates circuit means including a plurality of discretecomponents connected to a wire coil 51 to regulate the output currenttherein. More specifically, the discrete components include theidentical half wave circuit described above with respect to FIG. 5connected to one terminal of coil 51 which includes SCR 52, diodes 53and 54, zener diode 55 and resistor 56. Likewise, an identical half wavecircuit comprising SCR 57, diodes 58 and 59, zener diode 60 and resistor61 as connected to the other terminal of coil 51. Additionally, thecathodes of SCR devices 52 and 57 are connected together, and the anodesare connected together via diodes 62 and 63 to form a bridge circuit, asis well known in the art.

Referring now to FIG. 7, there is illustrated a stator 64 identical instructure to stator 1 of FIG. 1. Stator 64 includes a stationary annularring member 65 having an interradial surface 66 and an outer radialsurface 67. Ring member 65 also includes an upstanding annular flange 68which defines a cylindrical plane designated by the numeral 69 which isdisposed concentric with the axis of rotation of an engine's crankshaft(not shown). Stator 64 also includes four lens 70 projecting radiallyoutwardly from surface 67 that are integral with ring number 65 whichprovides a means for mounting stator 64 in a stationary position, andprovide a means for mounting a regulator circuit on stator 64. In thisembodiment, the regulator circuit is in the form of discrete componentsarranged to be connected to the central portion 71 of a bracket 72. Asshown best in FIG. 8, bracket 72 includes central portion 71 integrallyconnected to a pair of L-shaped end members 73, 74 at opposite endsthereof. A pair of screws 75, 76 extend through end members 73, 74respectively to mount bracket 72 on stator 64. As best seen in FIG. 7,end members 73, 74 are angled slightly with respect to central portion71 so that central portion 71 and the components of the regulatorcircuit are located radially inwardly of cylindrical plane 69 yet themounting for bracket 72 is radially outwardly of cylindrical plane 69.

FIG. 9 illustrates an alternate method of mounting the components of aregular circuit on stator 64. In this embodiment, the bracket 77 extendsbetween adjacent lens 70 and is spaced upwardly from the top surface oflens 70 so as to extend over the top edge of flange 68 by means of apair of spacers 78, 79. One spacer 78 over 79 is located adjacentopposite ends of bracket 77 and is adapted to receive a screw 80 or 81extending therethrough for mounting bracket 77 on stator 64. Once again,the components of the regulator circuit are located within cylindricalplane 69 with the bracket 77 mounted outside of plane 69.

Referring now to FIG. 10, there is illustrated another method ofmounting a regulator circuit to a stator 82. Stator 82 once again isidentical to stators 64 and 2 as previously described herein. In thisembodiment, however, the unusual components of the regulator circuit areattached to a circuit board 83. The circuit board 83, in turn, ismounted on stator 82 by means of SCR device 84. SCR device 84 may be anyof the SCR devices previously described herein i.e. devices 41, 46, 52or 57. As shown best in FIG. 11, SCR device 84 includes a plurality ofterminals 85 extending through circuit board 83 and soddered thereto inthe conventional manner. SCR device 84 also includes a mounting plate 86attached to one side thereof including an opening 87 formed therethroughfor receiving a screw 88 for mounting board 83 on one of four lens 89projecting from stator 82. Thus, as best shown in FIG. 10, circuit board83 and the components of regulator circuit are located radially inwardlyof cylindrical plane 90 while the actual mounting assembly is locatedradially outwardly of plane 90.

Various alternatives and modifications are contemplated as being withinthe scope of the following claims particularly pointing out anddistinctly claiming the subject matter regarded as the invention.

I claim:
 1. An alternator assembly for an internal combustion engine,comprising:stator means including at least one coil means cooperablewith a moving magnetic field created by magnets on a rotatable flywheelfor producing an electric output current in said coil means, and astationary annular ring member having an inner radial surface and anouter radial surface defining there between a cylindrical plane; enginecircuit means for monitoring a desired engine parameter; and mountingmeans for mounting said engine circuit means on said stator means sothat said engine circuit means is located radially outwardly of saidcylindrical plane.
 2. The alternator assembly of claim 1 wherein saidengine circuit means comprises a regulator circuit connected to saidcoil means for regulating said output current.
 3. The alternatorassembly of claim 1 wherein said engine circuit means comprises a safetyinterlock circuit.
 4. The alternator assembly of claim 1 wherein saidengine circuit means comprises an oil pressure start circuit.
 5. Thealternator assembly of claim 1 wherein said engine circuit meanscomprises a tachometer circuit.
 6. The alternator assembly of claim 1wherein said engine circuit means comprises an engine hour meteringcircuit.
 7. The alternator assembly of claim 1 wherein said enginecircuit means comprises an engine overheat circuit.
 8. An alternatorassembly for an internal combustion engine, comprising:stator meansincluding at least one coil means cooperable with a moving magneticfield created by magnets on a rotatable flywheel for producing anelectric output current in said coil means, and a stationary annularring member having an inner radial surface and an outer radial surfacedefining there between a cylindrical plane; engine circuit means formonitoring a desired engine parameter; and mounting means for mountingsaid engine circuit means on said stator means so that said enginecircuit means is located radially inwardly of said cylindrical plane. 9.The alternator assembly of claim 8 wherein said engine circuit meanscomprises a regulator circuit connected to said coil means forregulating said output current.
 10. The alternator assembly of claim 8wherein said engine circuit means comprises a safety interlock circuit.11. The alternator assembly of claim 8 wherein said engine circuit meanscomprises an oil pressure start circuit.
 12. The alternator assembly ofclaim 8 wherein said engine circuit means comprises a tachometercircuit.
 13. The alternator assembly of claim 8 wherein said enginecircuit means comprises an engine hour metering circuit.
 14. Thealternator assembly of claim 8 wherein said engine circuit meanscomprises an engine overheat circuit.
 15. An alternator assembly for aninternal combustion engine, comprising:stator means including at leastone coil means cooperable with a moving magnetic field created bymagnets on a rotatable flywheel for producing an electric output currentin said coil means, and a stationary annular ring member having an innerradial surface and an outer radial surface defining there between acylindrical plane; engine circuit means for monitoring a desired engineparameter; and mounting means for mounting said engine circuit means onsaid stator means, said mounting means includes a bracket supportingsaid engine circuit means so that said bracket is mounted radiallyoutwardly of said cylindrical plane and said engine circuit means islocated radially inwardly of said cylindrical plane.
 16. The alternatorassembly of claim 15 wherein said engine circuit means comprises aregulator circuit connected to said coil means for regulating saidoutput current.
 17. The alternator assembly of claim 15 wherein saidengine circuit means comprises a safety interlock circuit.
 18. Thealternator assembly of claim 15 wherein said engine circuit meanscomprises an oil pressure start circuit.
 19. The alternator assembly ofclaim 15 wherein said engine circuit means comprises a tachometercircuit.
 20. The alternator assembly of claim 15 wherein said enginecircuit means comprises an engine hour metering circuit.
 21. Thealternator assembly of claim 15 wherein said engine circuit meanscomprises an engine overheat circuit.